Mini COOPER S Workshop Manual

Category
Cars
Type
Workshop Manual
1
Chapter 1
Routine maintenance and servicing
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air pump drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . 9
Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . . 28
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Carburettor idle speed and mixture adjustment . . . . . . . . . . . . . . . . 26
Clutch hydraulic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch return stop adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contact breaker points check and adjustment . . . . . . . . . . . . . . . . . 20
Control box cleaning and inspection . . . . . . . . . . . . . . . . . . . . . . . . . 24
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Distributor cap, rotor arm and HT lead check . . . . . . . . . . . . . . . . . . 32
Distributor lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Door, boot and bonnet check and lubrication . . . . . . . . . . . . . . . . . . 27
Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drum brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamo check and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Emission control equipment check . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine/transmission oil and filter renewal . . . . . . . . . . . . . . . . . . . . . 13
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fan belt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front brake wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel filter renewal (fuel injection models) . . . . . . . . . . . . . . . . . . . . . . 37
Fuel system components, checks and lubrication . . . . . . . . . . . . . . 19
Handbrake check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Headlight beam alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ignition timing check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . 25
Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rear brake wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Seats and seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering and suspension lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 16
Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 6
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . . 18
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1•1
Contents
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
5
4
3
2
1
1•2 Servicing specifications
Lubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of “Weekly Checks
Capacities
Engine oil with filter change
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 litres
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 litres
Engine oil without filter change (approximate)
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 litres
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 litres
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres
Fuel tank
Saloon and Clubman (approximate):
Early models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 litres
Later models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 litres
Estate, Van and Pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 litres
1275 GT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 litres
Cooper S Mk III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 litres
Engine
Oil filter type:
Pre-1973 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X101 (cartridge type)
1974-on models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C103 (canister type)
Cooling system
Fan belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mm deflection of belt between crankshaft and dynamo/alternator
pulleys
Specified antifreeze mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30% antifreeze/70% water
Note: Refer to Chapter 3 for further details.
Fuel system - carburettor models
Air cleaner element type:
Pre-1973 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W131
1974-on models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W125
1990-on 1275 cc models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W250
Fuel system - fuel injection models
Air cleaner element type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available
Fuel filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available
Exhaust and emission control systems
Air pump drivebelt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mm deflection of belt between pulleys
Ignition system
Spark plugs:*
Type:
All models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC
998 cc engine models, 1987 to 1989 . . . . . . . . . . . . . . . . . . . . . . . Champion N12YCC or N12YC
998 cc engine models (1989-on) . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN12YCC or RN12YC
1275 cc engine models (1990-on) . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC
Electrode gap:
All Champion plug types except RN9YC and N12YC . . . . . . . . . . 0.8 mm
Champion RN9YC and N12YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm
HT leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-02, boxed set
*Spark plug types and electrode gaps are as recommended by Champion Spark Plug. If alternative plugs are used, refer to their manufacturer’s
recommendations.
Clutch
Clutch return stop clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Brakes
Minimum brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
Minimum brake pad thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
Handbrake lever travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 clicks of ratchet
Tyres
Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Weekly checks”
Torque wrench settings Nm lbf ft
Engine/transmission oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 25
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 45
Maintenance schedule 1•3
1
Every 250 miles (400 km) or weekly
mmRefer to “Weekly Checks”
Every 3000 miles (5000 km) or
3 months, whichever comes first
In addition to the items listed above, carry out the following:
mmAdjust the front and rear drum brakes (Section 3)
mmCheck the operation of the handbrake and adjust if
necessary (Section 4)
mmCheck the condition and security of the steering
and suspension components (Section 5)
mmInspect the underbody and the brake hydraulic
pipes and hoses (Section 6)
mmCheck the condition of the fuel lines (Section 6)
mmCheck the condition and security of the exhaust
system (Section 7)
mmCheck the condition of the fan belt and renew if
necessary (Section 8)
mmCheck the condition of the air pump drivebelt
(where applicable) and renew if necessary
(Section 9)
mmInspect the clutch hydraulic components
(Section 10)
mmCheck the condition of the seats and seat belts
(Section 11)
mmCheck the headlight beam alignment (Section 12)
Every 6000 miles (10 000 km) or
6 months, whichever comes first
In addition to the items listed above, carry out the following:
mmRenew the engine/transmission oil and filter
(Section 13)
mmCheck the condition of the front brake shoes and/or
pads, and renew if necessary (Section 14)
mmCheck the condition of the driveshaft gaiters
(Section 15)
mmLubricate the suspension and steering grease
points (Section 16)
mmCheck the condition of the rear brake shoes and
renew if necessary (Section 17)
mmCheck all underbonnet components and hoses for
fluid leaks (Section 18)
mmCheck and if necessary top up the carburettor
piston dashpot and lubricate the linkage
(Section 19)
Every 6000 miles (10 000 km) or
6 months, whichever comes first
(continued)
mmCheck the condition of the contact breaker points
and adjust or renew (Section 20)
mmLubricate the distributor (Section 21)
mmCheck and if necessary adjust the clutch return
stop (Section 22)
mmLubricate the dynamo bearing - early models
(Section 23)
mmClean and inspect the dynamo charging system
control box (Section 24)
mmCheck and if necessary adjust the ignition timing
(Section 25)
mmCheck and if necessary adjust the carburettor idle
speed and mixture settings (Section 26)
mmLubricate the locks and hinges (Section 27)
mmCheck the condition of the exterior trim and
paintwork (Section 28)
mmRoad test (Section 29)
Note: Renewal of the engine/transmission oil and filter at this service
interval is only necessary on pre-1985 models. On all other models,
oil and filter renewal is recommended at 12 000 miles/12 months.
Every 12 000 miles (20 000 km) or
12 months, whichever comes first
In addition to the items listed above, carry out the following:
mmRenew the air cleaner element (Section 30)
mmCheck and if necessary adjust the valve clearances
(Section 31)
mmInspect the distributor cap, rotor arm and HT leads
(Section 32)
mmRenew the spark plugs (Section 33)
mmCheck the emission control equipment (Section 34)
Every 24 000 miles (40 000 km) or
twenty four months, whichever
comes first
In addition to the items listed above, carry out the following:
mmRenew the coolant (Section 35)
mmRenew the brake fluid (Section 36)
mmRenew the fuel filter - fuel injection models
(Section 37)
The maintenance intervals in this manual
are provided with the assumption that you,
not the dealer, will be carrying out the work.
These are the average maintenance intervals
recommended by the manufacturer for
vehicles driven daily under normal conditions.
Obviously some variation of these intervals
may be expected depending on territory of
use, and conditions encountered. If you wish
to keep your vehicle in peak condition at all
times, you may wish to perform some of these
procedures more often. We encourage
frequent maintenance because it enhances
the efficiency, performance and resale value
of your vehicle.
If the vehicle is driven in dusty areas, used
to tow a trailer, driven frequently at slow
speeds (idling in traffic) or on short journeys,
more frequent maintenance intervals are
recommended.
1•4 Maintenance - component location
Underbonnet view of a 998 cc Mini 1000 Saloon
1 Brake master cylinder reservoir
2 Clutch master cylinder reservoir
3 Fuse block
4 Carburettor piston damper
5 Air cleaner
6 Windscreen wiper motor
7 Radiator pressure cap
8 Engine/transmission oil filler cap
9 Alternator
10 Engine/transmission oil dipstick
11 Distributor
12 Ignition coil
13 Vehicle identification plate
14 Clutch slave cylinder
15 Windscreen washer reservoir
Maintenance - component location 1•5
1
Underbonnet view of a 1275 cc Mini Cooper Saloon
(air cleaner removed for clarity)
1 Alternator
2 Ignition coil
3 Engine/transmission oil dipstick
4 Engine management (fuel
injection/ignition) ECU
5 Radiator pressure cap
6 Brake fluid reservoir cap
7 Brake system vacuum servo unit
8 Relay module
9 Fuel cut-off inertia switch
10 Manifold absolute pressure (MAP)
sensor fuel trap
11 Fuel return pipe
12 Fuel feed pipe
13 Accelerator cable
14 Throttle body assembly
15 Heater coolant valve
16 Charcoal canister purge valve
1•6 Maintenance - component location
Front underside view of a 998 cc Mini 1000 Saloon
1 Engine/transmission oil drain plug
2 Oil filter
3 Front suspension tie-bar
4 Disc brake caliper
5 Driveshaft outer CV joint
6 Front subframe
7 Subframe rear mounting
8 Offset sphere type inner CV joint
9 Gearchange extension rod
10 Battery positive cable
11 Steering tie-rod outer balljoint
12 Lower suspension arm
13 Exhaust bracket
Maintenance - component location 1•7
1
Rear underside view of a 998 cc Mini 1000 Saloon
1 Rear subframe
2 Rear brake wheel cylinder attachment 3 Exhaust rear silencer
4 Battery box
5 Exhaust mounting
6 Handbrake cable guide
7 Battery positive cable
1 Introduction
1This Chapter is designed to help the home
mechanic maintain his/her vehicle for safety,
economy, long life and peak performance.
2This Chapter contains a master
maintenance schedule, followed by Sections
dealing specifically with each task in the
schedule. Visual checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the engine compartment and
the underside of the vehicle for the locations
of the various components.
3Servicing your vehicle in accordance with
the mileage/time maintenance schedule and
the following Sections will provide a planned
maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
items but not others at the specified service
intervals will not produce the same results.
4As you service your vehicle, you will
discover that many of the procedures can -
and should - be grouped together, because of
the particular procedure being performed, or
because of the close proximity of two
otherwise-unrelated components to one
another. For example, if the vehicle is raised
for any reason, the exhaust should be
inspected at the same time as the suspension
and steering components.
5The first step of this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
Sections relevant to the work to be carried
out, then make a list and gather together all
the parts and tools required. If a problem is
encountered, seek advice from a parts
specialist or a dealer service department.
2 Intensive maintenance
1If, from the time the vehicle is new, the
routine maintenance schedule is followed
closely, and frequent checks are made of fluid
levels and high-wear items, as suggested
throughout this manual, the engine will be
kept in relatively good running condition, and
the need for additional work will be minimised.
2It is possible that there will be some times
when the engine is running poorly due to the
lack of regular maintenance. This is even more
likely if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
3If engine wear is suspected, a compression
test (refer to Chapter 2A) will provide valuable
information regarding the overall performance
of the main internal components. Such a test
can be used as a basis to decide on the
extent of the work to be carried out. If, for
example, a compression test indicates serious
internal engine wear, conventional
maintenance as described in this Chapter will
not greatly improve the performance of the
engine, and may prove a waste of time and
money, unless extensive overhaul work
(Chapter 2B) is carried out first.
4The following series of operations are those
often required to improve the performance of
a generally poor-running engine:
Primary operations
a) Clean, inspect and test the battery (See
“Weekly checks”).
b) Check all the engine-related fluids (See
“Weekly checks”).
c) Check and if necessary adjust the valve
clearances (Section 31).
d) Check the condition of the fan belt
(Section 8).
e) Top up the carburettor piston damper
(Section 19)
f) Check the condition and adjustment of
the contact breaker points (Section 20).
g) Inspect the distributor cap, rotor arm and
HT leads (Section 32).
h) Renew the spark plugs (Section 33).
i) Check and if necessary adjust the ignition
timing (Section 25).
j) Check the condition of the air cleaner
filter element and renew if necessary
(Section 30).
k) Check and if necessary adjust the
carburettor idle speed and mixture
settings (Section 26).
l) Renew the fuel filter - fuel injection
models (Section 37).
m)Check the condition of all hoses, and
check for fluid leaks (Section 18).
5If the above operations do not prove fully
effective, carry out the following operations:
Secondary operations
All the items listed under “Primary
operations”, plus the following:
a) Check the charging system (Chapter 5A).
b) Check the ignition system (Chapter 5B).
c) Check the fuel system (Chapter 4A and B).
d) Renew the distributor cap and rotor arm
(Section 32).
e) Renew the ignition HT leads (Section 32).
3 Drum brake adjustment
2
1As wear takes place on the brake shoe
friction material, the clearance between the
friction material and the inner circumference
of the brake drum will increase, resulting in
excessive brake pedal travel before the
brakes are applied. To compensate for this,
adjusters are provided at the rear of each
brake backplate, enabling the clearance
between the brake shoe and drum to be kept
to a minimum.
2At the front two adjusters are fitted to each
brake backplate. At the rear a single adjuster
is located at the top of each brake backplate.
Front brakes
3Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
4Each front brake has two adjusters of the
eccentric cam type, accessible from the rear
of each brake backplate. One of these
adjusters is located behind the steering arm
and insufficient clearance exists to enable an
ordinary brake adjusting spanner to be used.
Providing the adjuster is not excessively tight
or partially seized in the backplate, a 516 in AF
open-ended spanner can be used quite
successfully to turn the adjuster.
5Begin by turning one of the adjusters in the
forward direction of wheel rotation until the
wheel is locked (see illustration). Now back it
off slightly, until the wheel turns freely. The
brake drum may rub slightly in one or two
places as the wheel is turned. This is
acceptable providing the wheel does not bind.
Caution: If, when attempting to adjust the
brakes, the square-headed adjuster is
reluctant to turn, it is quite likely that it has
become seized in its housing. If this is the
case do not force it, or you will probably
break off the square head, necessitating
renewal of the complete backplate
assembly. Apply liberal amounts of
penetrating oil to the rear of the adjuster
and allow it to soak in. Now turn the
adjuster back and forth slightly, using
gentle force if necessary, increasing the
movement each time. When the adjuster
turns easily apply a multipurpose grease to
1•8 Maintenance procedures
Every 3000 miles or 3 months
3.5 Adjusting one of the front brake
adjusters with a brake adjusting spanner
the exposed portion of the adjuster at the
rear of the backplate and then turn it
through its entire travel. Preferably do this
with the brake drum removed.
6Turn the second adjuster also in the
direction of forward wheel rotation until the
drum locks again. Now back the adjuster off
until the wheel turns freely once more.
7Repeat this procedure for the other front
wheel and then lower the car to the ground.
Rear brakes
8Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”). Ensure
that the handbrake is off.
9Using a brake adjusting spanner, turn the
square-headed adjuster in a clockwise
direction (viewed from the rear of the
backplate) until the wheel is locked (see
illustration). The adjusters on the rear brakes
are even more prone to seizure than those at
the front. If the adjuster is reluctant to turn
attempt to free it off as described above. If
this fails, remove the rear brake drums and
brake shoes as described in Chapter 9, and
clean and lubricate the adjuster thoroughly.
When all is well, refit the brake assemblies
and start the adjustment procedure again.
10 Now turn the adjuster back a quarter of a
turn at a time until the wheel turns freely
without binding. A slight rubbing may be felt
when the wheel is turned slowly, indicating a
high spot on the drum or dust on the linings.
This is acceptable providing the drum does
not bind.
11 Repeat this procedure for the other rear
brake then, before lowering the car to the
ground, check the handbrake adjustment as
described in the following Section.
4 Handbrake check and
adjustment
2
1Adjustment of the handbrake cables is
usually only necessary after high mileage
when a slight stretching of the cables will have
taken place, or if the cables have been
removed.
2Before adjusting the handbrake check that
the footbrake is correctly adjusted as
described in Section 3.
3Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”).
4Apply the handbrake lever to the third notch
of the ratchet and check that the rear wheels
are locked. If not, adjust the handbrake as
follows.
5With the handbrake still applied to the third
click of the ratchet, tilt the front seats forward,
and on models having twin cables, tighten the
cable adjusting nuts at the base of the lever
until the rear wheels can only just be turned
by heavy hand pressure. On models having a
single front cable, slacken the locknut and
rotate the cable adjusting nut. When the
wheels can only just be turned by heavy hand
pressure, tighten the locknut (see
illustrations).
6Release the handbrake lever and ensure
that the wheels rotate freely. If satisfactory
lower the car to the ground.
5 Steering and suspension
check
2
Steering
1First check for wear in the steering tie-rod
outer balljoints. Turn the steering to left or
right lock sufficiently to allow the joints to be
observed. Now have an assistant turn the
steering wheel back and forth slightly. If there
is any side movement in the balljoint it must
be renewed. Similarly place your hand over
the rubber gaiter at the end of the rack
housing and feel for any excess free play of
the inner balljoint. If the condition of this joint
is suspect, a further investigation should be
carried out with the gaiter removed as
described in Chapter 10.
2Check the tightness of the steering column
clamp bolt at the base of the column. Any
slackness at this joint can also show up as
free play at the steering wheel.
Front suspension
3To inspect the front suspension, chock the
rear wheels then jack up the front of the car
and support it on axle stands (see “Jacking
and vehicle support”).
4Visually inspect the balljoint dust covers
and the steering gear gaiters for splits, chafing
or deterioration. Any wear of these
components will cause loss of lubricant,
together with dirt and water entry, resulting in
rapid deterioration of the balljoints or steering
gear.
5Grasp the roadwheel at the 12 o’clock and
6 o’clock positions and try to rock it. If any
movement is felt it is likely to be in one or
more of the following areas:
Hub bearings
6Continue rocking the wheel while your
assistant depresses the footbrake. If the
Every 3000 miles or 3 months 1•9
1
3.9 Adjusting the rear brakes
4.5a Handbrake adjustment on models with twin cables 4.5b Handbrake cable adjusting nut on models with a
single front cable
movement disappears or becomes less
severe, then the wheel hub bearings in the
swivel hub are at fault. Any perceptible
movement at all indicates wear in the hub
bearings, and they should be renewed as
described in Chapter 10.
Swivel hub balljoints
7Wear of the swivel hub balljoints is fairly
common on Minis and will be quite obvious
on inspection because the whole swivel hub
will appear to move in relation to the
suspension arms as the wheel is rocked. If
this is the case, the balljoints should be
adjusted, or if badly worn, renewed; these
procedures are contained in Chapter 10.
Suspension arm mountings
8Check for wear of the lower arm inner
mounting bushes where the arm is bolted to
the subframe. If the bushes are worn, the arm
will appear to move in and out as the wheel is
rocked.
9The upper arm inner roller bearings cannot
be inspected without partially dismantling the
suspension because the rubber cone spring
or displacer unit holds the arm in tension and
any wear will not be evident. It can be
removed for closer inspection if required as
described in Chapter 10; however, wear of the
upper arm and its bearings is uncommon.
10 With the brakes still firmly applied, try to
rotate the wheel back and forth. If any
movement is now felt, examine the tie-bar
between the lower suspension arm and
subframe for wear or deterioration of the
rubber bushes.
Rear suspension
11 To check the rear suspension for wear,
chock the front wheels then jack up the rear of
the car and support it on axle stands (see
“Jacking and vehicle support”).
12 Wear of the rear suspension components
can often be felt when driving the car as a
tendency for the rear of the vehicle to wander
over uneven road surfaces or when cornering.
To isolate the worn components, grasp the
roadwheel at the 12 o’clock and 6 o’clock
positions and try to rock it. If any movement is
felt, it is likely to be in one of the following
areas:
Hub bearings
13 Continue rocking the wheel while an
assistant depresses the footbrake. If the
movement disappears or becomes less
pronounced, then the bearings in the rear hub
are at fault. The bearings should be renewed if
there is any appreciable movement whatsoever.
Radius arm bearings
14 With the footbrake still applied, continue
rocking the wheel and observe the front of the
radius arm. If it can be seen to move
appreciably up and down, then wear has
taken place in the roller or plain bearing in the
radius arm, or on the pivot shaft. If this is the
case, the radius arm should be removed for
overhaul as described in Chapter 10.
6 Underbody and fuel/brake
line check
1
1With the vehicle raised and supported on
axle stands (see “Jacking and vehicle
support”), or over an inspection pit,
thoroughly inspect the underbody and wheel
arches for signs of damage and corrosion. In
particular, examine the bottom of the side
sills, and any concealed areas where mud can
collect. Where corrosion and rust is evident,
press and tap firmly on the panel with a
screwdriver, and check for any serious
corrosion which would necessitate repairs. If
the panel is not seriously corroded, clean
away the rust, and apply a new coating of
underseal. Refer to Chapter 11 for more
details of body repairs.
2At the same time, inspect the treated lower
body panels for stone damage and general
condition.
3Examine the subframes carefully,
particularly the side members of the rear
subframe. Corrosion here is a common
occurrence on Minis, particularly older
models, and is one of the main causes of
MOT test failure on these cars (see
illustration). Where corrosion has reached an
advanced stage, renewal of the subframe is
the only satisfactory cure.
4Inspect all of the fuel and brake lines on the
underbody for damage, rust, corrosion and
leakage. Also make sure that they are
correctly supported in their clips. The battery
positive cable which runs under the car from
front to rear is a common problem area as it is
prone to damage or chafing if not properly
routed or secured.
5Inspect the flexible brake hoses in the
vicinity of the backplates or front calipers,
where they are subjected to most movement
(see illustration). Bend them between the
fingers (but do not actually bend them double,
or the casing may be damaged) and check
that this does not reveal previously hidden
cracks, cuts or splits.
7 Exhaust system check
1
1With the engine cold (at least three hours
after the vehicle has been driven), check the
complete exhaust system, from its starting
point at the engine to the end of the tailpipe.
Ideally, this should be done on a hoist, where
unrestricted access is available; if a hoist is not
available, raise and support the vehicle on axle
stands (see “Jacking and vehicle support”).
1•10 Every 3000 miles or 3 months
6.3 Advanced state of corrosion on rear subframe side member 6.5 Inspect the flexible brake hoses in the vicinity of the
backplates
Wear in the rear hub bearings
can often be confirmed by
slowly turning the wheel with
your hand on the tyre. Worn
bearings usually exhibit a roughness
which can be felt as the wheel is turned.
2Check the pipes and connections for
evidence of leaks, severe corrosion, or
damage. Make sure that all brackets and
rubber mountings are in good condition, and
tight; if any of the mountings are to be
renewed, ensure that the replacements are of
the correct type. Failure of the rear mounting
rubber blocks on the rear subframe is a
common problem - check these carefully (see
illustrations). Leakage at any of the joints or in
other parts of the system will usually show up
as a black sooty stain in the vicinity of the leak.
3At the same time, inspect the underside of
the body for holes, corrosion, open seams,
etc. which may allow exhaust gases to enter
the passenger compartment. Seal all body
openings with silicone or body putty.
4Rattles and other noises can often be
traced to the exhaust system, especially the
rubber mountings. Try to move the system,
silencer(s) and catalytic converter. If any
components can touch the body or
suspension parts, secure the exhaust system
with new mountings.
8 Fan belt check and renewal
2
Note: If the car is fitted with exhaust emission
control equipment it will first be necessary to
remove the air pump drivebelt as described in
Section 9 to allow access to the fan belt.
Check and adjustment
1Release the three retaining lugs and remove
the engine ignition shield, if fitted. Rotate the
crankshaft so that the entire length of the fan
belt can be examined. On manual
transmission models, the engine can be
rotated quite easily by engaging top gear and
moving the car backwards or forwards to
allow the belt to be inspected. This should
only be done on level ground; and make sure
that the car cannot run away! An alternative
method, and the method that should be used
on automatic transmission models, is to press
the fan belt midway between the water pump
pulley and dynamo or alternator pulley and
then turn the fan blades.
2Examine the belt for cracks, splitting,
fraying or damage. Check also for signs of
glazing (shiny patches) and for separation of
the belt plies. Renew the fan belt if worn or
damaged.
3If the condition of the belt is satisfactory,
check the adjustment as follows.
4It is most important to keep the fan belt
correctly adjusted; If the belt is too loose it will
slip and wear rapidly, resulting in inefficient
operation of the water pump and dynamo or
alternator. If it is too tight, it will impose
excessive strain on the bearings of the water
pump, dynamo or alternator causing
premature failure of these components.
5The fan belt tension is correct when there
is 13 mm of fan belt deflection, using light
finger pressure, at a point midway between
the crankshaft and dynamo or alternator
pulleys.
6To adjust the fan belt, slacken the mounting
bolts of the dynamo or alternator, and also the
nut on the adjusting arm located below the
water pump (see illustration). Now move the
unit either in or out until the correct tension is
obtained. It is easier if the adjusting arm nut is
only slackened a little so it requires some force
to move the dynamo or alternator. In this way
the tension of the belt can be arrived at more
quickly than by making frequent adjustments.
If difficulty is experienced in moving the
dynamo or alternator away from the engine, a
long spanner or bar placed behind the unit and
resting against the block serves as a very good
lever and can be held in position while the
adjusting and mounting bolts are fully
tightened. When levering on an alternator, only
lever on the drive end or damage may occur.
7When the tension is correct, tighten the
adjusting arm nut first, followed by the
mounting bolts.
Renewal
8To remove the fan belt, slacken the two
dynamo or alternator upper mountings and
the nut on the adjusting arm below the water
pump (see illustrations).
Every 3000 miles or 3 months 1•11
1
8.6 Dynamo adjusting arm nut located
below the water pump
7.2a Exhaust front mounting block . . . 7.2b . . . and rear mounting block on rear
subframe
8.8a Dynamo mountings and adjustment points
1 Adjustment arm retaining nuts
2 Securing nut and bolt (rear) 3 Securing nut and bolt (front)
When checking the exhaust,
pay particular attention to the
mounting on the transmission.
Movement of the engine
causes this mounting to work loose,
causing an annoying squeak or rattle
when accelerating and decelerating.
Turning the engine will be
easier if the spark plugs are
removed first - see Section 33.
9Push the dynamo or alternator toward the
engine and lift the old belt off the three
pulleys. Feed the belt over each fan blade in
turn and withdraw it from behind the fan
cowling at the special gap just below the top
hose (see illustration).
10 Fit the new belt over the fan blades in the
same way and then place it in position on the
three pulleys.
11 Adjust the fan belt tension as described
previously then refit the air pump drivebelt,
where applicable, as described in the
following Section. Note:After fitting a new fan
belt, check and if necessary readjust the
tension after 250 miles (400 km).
9 Air pump drivebelt check
and renewal
2
Check and adjustment
1The checks and adjustment procedure for
the air pump drivebelt are basically the same
as described in Section 9 for the fan belt.
Adjust the tension of the drivebelt so that
there is 13 mm deflection of the belt, using
thumb pressure, at a point midway between
the two pulleys.
Renewal
2Release the three retaining lugs and remove
the engine ignition shield, if fitted.
3Undo and remove the two bolts securing
the radiator upper mounting bracket to the
radiator.
4Unscrew the radiator filler cap and slacken
the top hose securing clips. Carefully ease the
radiator as far as possible toward the wing
valance. Place a container beneath the engine
to catch the small quantity of coolant that will
be lost as the top hose is released.
Warning:If the engine is hot,
take precautions against
scalding.
5Slacken the air pump pivot and adjusting
link bolts, push the pump in toward the
engine, and slip the drivebelt off the two
pulleys.
6Feed the belt between the fan blades and
the radiator cowling at the top as the blades
are rotated. Now pull the belt out from
between the fan and radiator.
7Refitting the drivebelt is the reverse
sequence to removal, adjusting the tension as
described previously. Top up the cooling
system as described in “Weekly Checks” on
completion.
10 Clutch hydraulic check
1
1Check that the clutch pedal moves
smoothly and easily through its full travel, and
that the clutch itself functions correctly, with
no trace of slip or drag.
2Apply a few drops of light oil to the clutch
pedal pivot.
3From within the engine compartment check
the condition of the fluid lines and hoses.
Check for signs of fluid leaks around the slave
cylinder rubber boot or from the feed pipe and
hose. Apply a few drops of oil to the clutch
operating lever clevis pin and the pivot on the
flywheel housing.
11 Seats and seat belt check
1
1Check that the seats are securely attached
to the floor crossmember and that there is no
sign of corrosion anywhere near the
mountings. Check that the seats release and
then lock in place when the release
mechanism is operated.
2Check the seat belts for satisfactory
operation and condition. Inspect the webbing
for fraying and cuts. Check that they retract
smoothly and without binding into their reels.
3Check the seat belt mountings, ensuring
that all the bolts are securely tightened.
12 Headlight beam alignment
check
5
Accurate adjustment of the headlight beam
is only possible using optical beam-setting
equipment, and this work should therefore be
carried out by a Rover dealer or service
station with the necessary facilities.
Basic adjustments can be carried out in an
emergency, and further details are given in
Chapter 12.
1•12 Every 3000 miles or 3 months
8.8b Alternator mounting and adjustment points
1 Adjustment arm fixings
2 Securing nut and bolt (rear) 3 Securing nut and bolt (front)
8.9 The gap in the radiator shroud of early models (arrowed) to
allow removal and refitting of the fan belt
13 Engine/transmission oil and
filter renewal
2
1Frequent oil changes are the best
preventive maintenance the home mechanic
can give the engine, because ageing oil
becomes diluted and contaminated, which
leads to premature engine wear.
2Make sure that you have all the necessary
tools before you begin this procedure. You
should also have plenty of rags or newspapers
handy, for mopping up any spills. The oil
should preferably be changed when the
engine is still fully warmed-up to normal
operating temperature, just after a run; warm
oil and sludge will flow out more easily. Take
care, however, not to touch the exhaust or any
other hot parts of the engine when working
under the vehicle. To avoid any possibility of
scalding, and to protect yourself from possible
skin irritants and other harmful contaminants
in used engine oils, it is advisable to wear
gloves when carrying out this work. Access to
the underside of the vehicle is greatly
improved if the vehicle can be lifted on a hoist,
driven onto ramps, or supported by axle
stands. (see “Jacking and vehicle support”).
Whichever method is chosen, make sure that
the vehicle remains level, or if it is at an angle,
that the drain point is at the lowest point.
Oil draining
3Position the draining container under the
drain plug on the side of the transmission
casing, and unscrew the plug (see
illustration). If possible, try to keep the plug
pressed into the sump while unscrewing it by
hand the last couple of turns.
4Allow the oil to drain into the container (see
Haynes Hint), and check the condition of the
plug’s sealing washer; renew it if worn or
damaged. Also wipe off any metal particles
that may have accumulated on the magnet.
5Allow some time for the old oil to drain,
noting that it may be necessary to reposition
the container as the oil flow slows to a trickle;
when the oil has completely drained, wipe
clean the drain plug and its threads in the
transmission and refit the plug, tightening it to
the specified torque.
Oil filter renewal
6The oil filter is located underneath the
dynamo or alternator on the forward-facing
side of the engine. On early manual
transmission models the filter is of the
disposable cartridge type contained within an
aluminium bowl. On later models a throwaway
canister is used. All automatic transmission
models utilise the cartridge type filter. To
renew the filter proceed as follows.
Cartridge type
7Reposition the draining container under the
oil filter then undo and remove the long centre
bolt securing the bowl to the housing (see
illustration). On some models it may be
advantageous to remove the grille panel, as
space is rather limited.
8With the bolts released, carefully lift away
the filter bowl, which contains the filters and
will also be full of oil.
9Discard the old filter element but first make
sure that the metal pressure plate has not
stuck to the bottom of it. Now thoroughly
clean out the filter bowl, the bolt, and the
parts associated with it, using paraffin or a
suitable solvent (see illustration) Dry with a
lint free cloth
10 A rubber sealing ring is located in a
groove round the head of the filter housing
and forms an effective leak-proof joint
between the housing and the filter bowl. A
new rubber sealing ring is supplied with each
new filter element.
11 Carefully prise out the old sealing ring
from the locating groove. If the ring has
become hard and is difficult to move take
great care not to damage the sides of the
sealing ring groove.
12 With the old ring removed, fit the new ring
in the groove at four equidistant points and
press it home a segment at a time. Do not
insert the ring at just one point and work
round the groove pressing it home as, using
this method, it is easy to stretch the ring and
be left with a small loop of rubber which will
not fit into the locating groove (see
illustration).
13 Reassemble the oil filter assembly by first
passing up the bolt through the hole in the
bottom of the bowl, with a steel washer under
the bolt’s head and a rubber or felt washer on
top of the steel washer and next to the filter
bowl.
14 Slide the spring over the bolt followed by
the other steel washer, the remaining rubber
washer and finally the filter pressure plate
concave face downwards.
15 After fitting the new element to the bowl,
position the bowl on the rubber sealing ring
then insert and hand tighten the bolt. Before
finally tightening the centre bolt, ensure that
the lip of the filter bowl is resting squarely on
the rubber sealing ring and is not offset or
seated off the ring. If the bowl is not seating
properly, rotate it until it is. Run the engine
and check the bowl for leaks.
Every 6000 miles or 6 months 1•13
1
13.3 Engine/transmission oil drain plug
(arrowed)
13.7 Cartridge type oil filter and retaining
bolt as seen from below 13.12 Fitting a new cartridge type oil filter
sealing ring
13.9 Components of the cartridge type oil
filter
Keep the drain plug pressed into the
sump while unscrewing it by hand the
last couple of turns. As the plug
releases, move it away sharply so the
stream of oil issuing from the sump
runs into the container, not up your
sleeve!
Canister type
16 Reposition the draining container under
the oil filter then, using a suitable filter removal
tool if necessary, slacken the canister initially,
then unscrew it by hand the rest of the way;
be prepared for some oil spillage (see
illustration). Empty the oil in the old canister
into the container.
17 Using a clean, lint-free rag, wipe clean the
cylinder block around the filter housing.
Check the old canister to make sure that the
rubber sealing ring hasn’t stuck to the filter
housing; if it has, carefully remove it.
18 Apply a light coating of clean engine oil to
the sealing ring on the new canister. Screw
the canister into position on the housing until
it seats, then tighten it firmly by hand only - do
not use any tools.
19 Remove the old oil and all tools from
under the vehicle, then lower the vehicle to
the ground.
Oil filling
20 Remove the dipstick and the oil filler cap
from the engine. Fill the engine with oil, using
the correct grade and type of oil, (see
Specifications). Pour in half the specified
quantity of oil first, then wait a few minutes for
the oil to fall to the transmission casing. Take
care during this operation, particularly in cold
weather as it is all to easy to fill up the rocker
cover before the oil drains down into the
engine, with very messy results as it overflows
out of the filler neck. Continue adding oil a
small quantity at a time, until the level is up to
the lower mark on the dipstick. Adding
approximately 0.5 litres will raise the level to
the upper mark on the dipstick.
21 Start the engine. The oil pressure warning
light will take a few seconds to go out while
the new filter fills with oil; do not race the
engine while the light is on. Run the engine for
a few minutes, while checking for leaks
around the oil filter seal and the drain plug.
22 Switch off the engine, and wait a few
minutes for the oil to settle in the transmission
once more. With the new oil circulated and
the filter now completely full, recheck the level
on the dipstick, and add more oil as
necessary.
23 Dispose of the used engine oil safely and
in accordance with environmental regulations
(see “General repair procedures”).
14 Front brake wear check
1
Warning: The dust created by wear
of the shoes may contain asbestos,
which is a health hazard. Never
blow it out with compressed air,
and don’t inhale any of it. An approved filtering
mask should be worn when working on the
brakes. DO NOT use petrol or petroleum-
based solvents to clean brake parts; use brake
cleaner or methylated spirit only.
Drum brake models
1After high mileage the friction linings on the
brake shoes will have worn, and it will
therefore be necessary to fit replacement
shoes with new linings.
2Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.
3Slacken off the brake shoe adjuster(s) from
behind the backplate, and then undo and
remove the two brake drum retaining screws.
4Remove the brake drum from the wheel
hub. If the drum is tight, gently tap its
circumference with a soft-faced mallet.
5Brush and wipe away all traces of asbestos
dust from the brake shoes, wheel cylinders
and backplate, and also from the inner
circumference of the brake drum.
6Inspect the friction material and renew the
brake shoes as described in Chapter 9 if they
have worn down to less than the specified
minimum thickness.
7The brake shoes must also be renewed if
there is any sign of hydraulic fluid
contamination of the linings due to a leaking
brake wheel cylinder. If this is the case, the
cause of the leak must be traced and rectified
before fitting new brake shoes.
8Brake shoes should always be renewed as
complete sets (four shoes to a set), otherwise
uneven braking and pulling to one side may
occur.
9It is advisable to check that the brake wheel
cylinders are operating correctly before
proceeding further. To do this hold the brake
shoes in position using two screwdrivers while
an assistant very slowly depresses the brake
pedal slightly. Check that the wheel cylinder
pistons move out as the pedal is depressed,
and return when the pedal is released. If this is
not the case, it is quite likely that one of the
wheel cylinder pistons is seized and the cylinder
should therefore be renewed (Chapter 9).
10 Also check the condition of the brake
drum, If it is deeply scored on its inner
circumference it may be possible to have it
skimmed at an engineering works. If the
scoring is severe, renewal will be necessary
Disc brake models
11 Jack up the front or rear of the vehicle in
turn, and support it on axle stands (see
“Jacking and vehicle support”).
12 For better access to the brake calipers,
remove the roadwheels.
13 Look through the opening in the front of
the caliper, and check that the thickness of
the friction lining material on each of the pads
is not less than the recommended minimum
thickness given in the Specifications (see
Haynes Hint). If any one of the brake pads
has worn down to, or below, the specified
limit, all four pads must be renewed as a set
(ie all the front pads).
14 For a comprehensive check, the brake
pads should be removed and cleaned. The
operation of the brake calipers can then be
checked, and the brake discs can be fully
examined. Refer to Chapter 9 for details.
15 Driveshaft gaiter check
1
With the vehicle raised and securely
supported on stands (see “Jacking and
vehicle support”), turn the steering onto full
lock, then slowly rotate the roadwheel.
Inspect the condition of the outer constant
velocity (CV) joint rubber gaiters, squeezing
the gaiters to open out the folds. Check for
signs of cracking, splits or deterioration of the
rubber, which may allow the grease to
escape, and lead to water and grit entry into
the joint. Also check the security and
condition of the retaining clips. Repeat these
checks on the inner CV joints where offset
sphere type joints are fitted. If any damage or
deterioration is found, the gaiters should be
renewed as described in Chapter 8.
At the same time, check the general condition
of the CV joints themselves by first holding the
1•14 Every 6000 miles or 6 months
13.16 Canister type oil filter
1 Housing
2 Sealing ring 3 Filter
Look through the opening in the caliper
and check the thickness of the friction
lining material on the brake pads
driveshaft and attempting to rotate the wheel.
Repeat this check by holding the inner joint and
attempting to rotate the driveshaft. Any
appreciable movement indicates wear in the
joints, wear in the driveshaft splines, or a loose
driveshaft retaining nut.
16 Steering and suspension
lubrication
1
1Unlike most modern cars, there are a number
of steering and suspension joints on the Mini
which require regular attention. Provision for
lubrication of these joints is by means of a
grease nipple, to which a grease gun can be
engaged. The grease nipples are located in the
following areas (see illustrations):
a) Steering swivel hub; two nipples, one
upper and one lower on each side.
b) Upper suspension arm inner pivot; one
nipple on each arm.
c) Rear radius arm pivot; one nipple on each
pivot. Remove the rubber blanking plug to
expose the nipple on early models.
2When lubricating the front grease nipples it
is preferable to raise the front of the car and
support it on axle stands (see “Jacking and
vehicle support”) so that the load is taken off
the suspension. This will allow the grease to
penetrate into the joints more effectively. The
rear radius arm pivots can be lubricated with
the car on its roadwheels if wished.
3With the car raised and suitably supported,
wipe clean the area all round the grease
nipple and the nipple itself. Engage the head
of a grease gun, filled with the specified
grease, squarely onto the nipple, keeping it
pushed fully home. Operate the gun until
grease can be seen to appear from under the
dust cover over the joint or from around the
side of the pivot bushes.
4When lubricating the rear radius arm pivots, a
generous amount of grease will be needed each
side, quite a bit more than was required for the
front suspension joints. It probably won’t be
possible to tell when sufficient has been
applied, unless you look underneath at the inner
attachment on the subframe, it may be possible
to see it appear around the inner pivot; add a bit
more if in doubt .This is a vitally important area
on the Mini and it must be well lubricated.
5Although not actually part of the steering
and suspension, the handbrake cable guides
and the moving sectors on the rear subframe
should be lubricated at this time to ensure
smooth operation. There are no grease
nipples, so the grease should be applied with
a wooden spatula or similar tool to lubricate
these areas thoroughly.
17 Rear brake wear check
1
The procedure for checking the rear brake
components is the same as described in
Section 14 for models with drum brakes.
18 Underbonnet check for fluid
leaks and hose condition
1
General
1High temperatures in the engine
compartment can cause the deterioration of
the rubber and plastic hoses used for engine,
accessory and emission systems operation.
Periodic inspection should be made for
cracks, loose clamps, material hardening and
leaks.
2Carefully check the large top and bottom
radiator hoses, along with the other smaller-
diameter cooling system hoses and metal
pipes; do not forget the heater hoses/pipes
which run from the engine to the bulkhead.
Inspect each hose along its entire length,
replacing any that are cracked, swollen or
shows signs of deterioration. Cracks may
become more apparent if the hose is
squeezed (see Haynes Hint).
3Make sure that all hose connections are
tight. If the spring clamps that are used to
secure some of the hoses appear to be
slackening, they should be renewed to
prevent the possibility of leaks.
4Some other hoses are secured to their
fittings with screw type clips. Where screw
type clips are used, check to be sure they
haven’t slackened, allowing the hose to leak.
If clamps or screw type clips aren’t used,
make sure the hose has not expanded and/or
hardened where it slips over the fitting,
allowing it to leak.
5Check all fluid reservoirs, filler caps, drain
plugs and fittings etc, looking for any signs of
leakage of oil, transmission and/or brake
hydraulic fluid or coolant. If the vehicle is
regularly parked in the same place, close
inspection of the ground underneath it will
soon show any leaks. As soon as a leak is
detected, its source must be traced and
rectified. Where oil has been leaking for some
time, it is usually necessary to use a steam
cleaner, pressure washer or similar, to clean
away the accumulated dirt, so that the exact
source of the leak can be identified.
Vacuum hoses
6It’s quite common for vacuum hoses,
especially those in the emissions system, to
be numbered or colour-coded, or to be
identified by coloured stripes moulded into
them. Various systems require hoses with
different wall thicknesses, collapse resistance
and temperature resistance. When renewing
hoses, be sure the new ones are made of the
same material.
7Often the only effective way to check a
hose is to remove it completely from the
vehicle. If more than one hose is removed, be
sure to label the hoses and fittings to ensure
correct installation.
8When checking vacuum hoses, be sure to
include any plastic T-fittings in the check.
Every 6000 miles or 6 months 1•15
1
16.1a Lubricating the swivel hub upper
grease nipple . . . 16.1b . . . the upper suspension arm inner
pivot grease nipple . . . 16.1c . . . and the rear radius arm pivot
grease nipple
A leak in the cooling system will usually
show up as white or rust coloured
deposits on the area adjoining the leak
Inspect the fittings for cracks, and check the
hose where it fits over the fitting for distortion,
which could cause leakage.
9A small piece of vacuum hose can be used
as a stethoscope to detect vacuum leaks.
Hold one end of the hose to your ear, and
probe around vacuum hoses and fittings,
listening for the “hissing” sound characteristic
of a vacuum leak.
Warning: When probing with the
vacuum hose stethoscope, be
very careful not to come into
contact with moving engine
components such as the fan or fan belt.
Fuel hoses
Warning: Before carrying out the
following operation, refer to the
precautions given in “Safety
first!” at the beginning of this
manual, and follow them implicitly. Petrol
is a highly dangerous and volatile liquid,
and the precautions necessary when
handling it cannot be overstressed.
10 Check all fuel hoses for deterioration and
chafing. Check especially for cracks in areas
where the hose bends, and also just before
fittings, such as where a hose attaches to the
carburettor.
11 Spring-type clamps are commonly used
on fuel lines. These clamps often lose their
tension over a period of time, and can be
“sprung” during removal. Replace all spring-
type clamps with screw clips whenever a hose
is replaced.
Metal lines
12 Sections of metal piping are often used
for fuel line between the fuel tank, filter and
the engine. Check carefully to be sure the
piping has not been bent or crimped, and that
cracks have not started in the line.
13 If a section of metal fuel line must be
renewed, only seamless steel piping should
be used, since copper and aluminium piping
don’t have the strength necessary to
withstand normal engine vibration.
14 Check the metal brake lines where they
enter the master cylinder for cracks in the
lines or loose fittings. Any sign of brake fluid
leakage calls for an immediate and thorough
inspection of the brake system.
19 Fuel system components,
checks and lubrication
1
1Sparingly apply a few drops of light oil to the
throttle spindles, accelerator cable and the
pedal pivot. Similarly lubricate the exposed
ends of the choke cable (where fitted).
2Check that there is a small amount of
slackness in the cable so that the throttle linkage
closes fully with the accelerator pedal released.
Also check that full throttle can be obtained with
the accelerator pedal fully depressed.
3If there is any doubt about the cable
adjustment, refer to the relevant Parts of
Chapter 4 for the full adjustment procedure.
4On carburettor models, unscrew the piston
damper cap from the top of the carburettor
dashpot (see illustration). Top up the damper
with engine oil until the level is 13.0 mm above
the top of the hollow piston rod.
5Slowly push the damper back into the
piston and screw on the cap taking care not
to cross-thread it.
20 Contact breaker points
check and adjustment
3
Refer to Chapter 5B.
21 Distributor lubrication
1
1It is important that the distributor cam is
lightly lubricated with general purpose grease,
and that the contact breaker arm, centrifugal
advance weights and cam spindle are also
very lightly lubricated.
2Great care should be taken not to use too
much lubricant, as any excess that might find
its way onto the contact breaker points could
cause burning and misfiring.
3If an ignition shield is fitted over the front of
the engine, release the three plastic retaining
lugs and lift away the shield. Detach the two
spring clips or undo the two screws securing
the distributor cap to the distributor body and
lift off the cap.
4To gain access to the cam spindle, lift away
the rotor arm. Drop no more than two drops of
engine oil onto the felt pad or screw head (see
illustration). This will run down the spindle
when the engine is hot and lubricate the
bearings. The centrifugal advance weights
can be lubricated by dropping two or three
drops of engine oil through one of the holes or
slots in the distributor baseplate. No more
than one drop of oil should be applied to the
contact breaker arm pivot post.
5Refit the rotor arm, distributor cap and
ignition shield on completion.
22 Clutch return stop
adjustment
1
Note: As friction linings of the clutch disc wear,
the distance between the clutch release bearing
and the clutch thrust plate will decrease. The
pressure plate will then move in closer to the
clutch disc to compensate for wear. Unless the
wear is taken up by adjustment of the stop
located between the flywheel housing and the
1•16 Every 6000 miles or 6 months
19.4 Top up the piston damper on
carburettor models
21.4 Distributor lubrication points
1 Contact breaker cam
2 Contact breaker pivot post 3 Centrifugal weights lubrication point
4 Cam spindle
operating lever, the clutch will start to slip. On
later models fitted with the verto type clutch, the
assembly is self-adjusting and the following
procedure will not be necessary.
1To carry out the adjustment, first disconnect
the clutch operating lever return spring.
2Pull the operating lever away from the
engine until all the free play is eliminated.
3Hold the lever in this position and measure
the gap between the lever and the head of the
stop using feeler blades (see illustration).
4If necessary, slacken the locknut and adjust
the stop bolt until the specified gap is
achieved. Then tighten the locknut.
23 Dynamo check and
lubrication
1
Dynamo checks and lubrication consist
simply of checking the fan belt condition and
tension (Section 8) and adding a few drops of
engine oil to the dynamo rear bearing
lubricating hole.
24 Control box cleaning and
inspection
1
On dynamo equipped models, remove the
control box cover and check the cut-out and
regulator contacts. If they are dirty or rough or
burnt, place a piece of fine glasspaper (do not
use emery paper or carborundum paper)
between the cut-out contacts, close them
manually, and draw the glasspaper through
several times.
Clean the regulator contacts in exactly the
same way, but use emery or carborundum
paper and not glasspaper. Carefully clean
both sets of contacts from all traces of dust
with a rag moistened in methylated spirit. Refit
the cover on completion.
25 Ignition timing check and
adjustment
3
Refer to Chapter 5B.
26 Carburettor idle speed and
mixture adjustment
3
Refer to Chapter 4A.
27 Door, boot and bonnet
check and lubrication
1
1Check that the doors, bonnet and boot lid
close securely. Check that the bonnet safety
catch operates correctly. Check the operation
of the door check straps.
2Lubricate the hinges, door check straps,
the striker plates and the bonnet catch
sparingly with a little oil or grease.
3If any of the doors, bonnet or boot lid do not
close effectively or appear not to be flush with
the surrounding panels, carry out the adjustment
procedures contained in Chapter 11.
28 Bodywork, paint and exterior
trim check
1
1The best time to carry out this check is after
the car has been washed so that any surface
blemish or scratch will be clearly evident and
not hidden by a film of dirt.
2Starting at one front corner check the
paintwork all around the car, looking for minor
scratches or more serious dents. Check all
the trim and make sure that it is securely
attached over its entire length.
3Check the security of all door locks, door
mirrors, badges, bumpers, front grille and
wheel trim. Anything found loose, or in need of
further attention should be done with reference
to the relevant Chapters of this manual.
4Rectify any problems noticed with the
paintwork or body panels (see Chapter 11).
29 Road test
1
Check the operation and
performance of the braking
system
1Make sure that the vehicle does not pull to
one side when braking, and that the wheels
do not lock when braking hard.
2Check that there is no vibration through the
steering when braking.
3Check that the handbrake operates
correctly, without excessive movement of the
lever, and that it holds the vehicle stationary
on a slope.
4With the engine switched off, test the
operation of the brake servo unit (where fitted)
as follows. Depress the footbrake four or five
times to exhaust the vacuum, then start the
engine. As the engine starts, there should be a
noticeable “give” in the brake pedal as vacuum
builds up. Allow the engine to run for at least
two minutes, and then switch it off. If the brake
pedal is now depressed again, it should be
possible to detect a hiss from the servo as the
pedal is depressed. After about four or five
applications, no further hissing should be heard,
and the pedal should feel considerably harder.
Steering and suspension
5Check for any abnormalities in the steering,
suspension, handling or road “feel”.
6Drive the vehicle, and check that there are
no unusual vibrations or noises.
7Check that the steering feels positive, with
no excessive sloppiness or roughness, and
check for any suspension noises when
cornering and driving over bumps.
Drivetrain
8Check the performance of the engine,
transmission and driveline.
9Check that the engine starts correctly, both
when cold and when hot.
10 Listen for any unusual noises from the
engine and transmission.
11 Make sure that the engine runs smoothly
when idling, and that there is no hesitation
when accelerating.
12 On manual transmission models, check
that all gears can be engaged smoothly
without noise, and that the gear lever action is
not abnormally vague or “notchy”.
13 On automatic transmission models, make
sure that the drive seems smooth without
jerks or engine speed “flare-ups”. Check that
all the gear positions can be selected with the
vehicle at rest.
Clutch
14 Check that the clutch pedal moves
smoothly and easily through its full travel, and
that the clutch itself functions correctly, with
no trace of slip or drag. If the movement is
uneven or stiff in places, check the system
components with reference to Chapter 6.
Instruments and electrical
equipment
15 Check the operation of all instruments
and electrical equipment.
16 Make sure that all instruments read
correctly, and switch on all electrical
equipment in turn, to check that it functions
properly.
17 Test the operation of the brake failure
warning system (where fitted) by pressing the
test switch located next to the heated rear
window switch. When pressed, the switch
should light and go out when released.
18 If the light should come on when driving,
the brake fluid level should be checked (and
topped up, if necessary), as soon as possible.
Every 6000 miles or 6 months 1•17
1
22.3 Using feeler blades to measure the
clutch return stop clearance
30.13b Lift off the lid and remove the
element
30 Air cleaner element renewal
1
Carburettor models except
Cooper S
1On models with an air intake duct over the
top of the engine, unscrew the two nuts
securing the duct to the rocker cover studs.
Release the clip and disconnect the duct from
the air cleaner body.
2Undo and remove the single wing nut and
washer on early models, or the twin wing bolts
and washers on later models, securing the air
cleaner to the carburettor
3If the air cleaner is retained by a single wing
nut lift off the air cleaner top cover. Detach the
rocker cover hose, then lift the air cleaner
body off the carburettor, tip it up at the front
and slide it sideways until it is clear of the long
retaining stud and can be lifted away. Recover
the sealing ring.
4If the air cleaner is retained by two wing
nuts, detach the hot air duct (where fitted) and
then lift the air cleaner body off the
carburettor.
5With the air cleaner removed from the
engine, recover the rubber sealing ring if it
stayed behind on the carburettor flange.
6Lift off the air cleaner cover and withdraw
the paper element. On the later type moulded
plastic air cleaners the cover is removed by
prising it off with a screwdriver inserted in the
slots on the periphery of the cover (see
illustrations).
7Thoroughly clean the inside of the air
cleaner body.
8Refit the air cleaner and element using a
reverse of the removal procedure. Make sure
that where an alignment arrow is stamped on
the top cover, it is pointing toward the
location lug on the air cleaner body (see
illustration). Ensure also that the rubber
sealing ring is in position before refitting the
air cleaner.
9If the air cleaner body incorporates an
adjustable air intake spout, this should be
positioned adjacent to the exhaust manifold in
winter and away from it in summer.
Cooper S carburettor models
10 Undo and remove the two wing bolts and
washers and lift off the air cleaner top cover.
Lift out the paper elements and thoroughly
clean the inside of the air cleaner body.
11 The air cleaner body may be removed if
necessary after disconnecting the engine
breather pipe and the throttle return spring.
Take care not to lose the two rubber sealing
washers from the carburettor flanges.
12 Refitting the air cleaner and elements is
the reverse of the removal procedure.
Fuel injection models
13 Release the four retaining clips, then
slacken and remove the three screws
securing the air cleaner assembly to the
throttle body, and lift off the air cleaner lid.
Remove the filter element (see illustrations).
14 Wipe the body of the air cleaner clean,
then fit the new element, ensuring that it is
correctly seated.
15 Refit the air cleaner lid, and secure it in
position with the retaining screws (tightening
them securely) and clips.
31 Valve clearance adjustment
2
Refer to Chapter 2A.
32 Distributor cap, rotor arm
and HT lead check
1
Warning: Voltages produced by
an electronic ignition system are
considerably higher than those
produced by conventional
ignition systems. Extreme care must be
taken when working on the system if the
ignition is switched on. Persons with
surgically-implanted cardiac pacemaker
devices should keep well clear of the
ignition circuits, components and test
equipment.
1The spark plug (HT) leads should be
inspected one at a time, to prevent mixing up
the firing order, which is essential for proper
engine operation. Gain access to the leads
and disconnect them as described for the
spark plug check and renewal.
2Check inside the boot for corrosion, which
will look like a white crusty powder. Clean this
off as much as possible; if it is excessive, or if
cleaning leaves the metal connector too badly
corroded to be fit for further use, the lead
must be renewed. Push the lead and boot
back onto the end of the spark plug. The boot
should fit tightly onto the end of the plug - if it
doesn’t, remove the lead and use pliers
carefully to crimp the metal connector inside
the boot until the fit is snug.
3Using a clean rag, wipe the entire length of
the lead to remove built-up dirt and grease.
1•18 Every 12 000 miles or 12 months
30.6b . . . and lift out the element30.6a Prise off the later type air cleaner
moulded plastic cover . . .
30.8 Make sure the alignment arrow is
toward the lug on the air cleaner body 30.13a On fuel injection models, release
the clips (three arrowed) and remove the
screws
Once the lead is clean, check for burns,
cracks and other damage. Do not bend the
lead sharply, because the conductor might
break.
4Inspect the remaining spark plug (HT)
leads, ensuring that each is securely fastened
at the distributor cap and spark plug when the
check is complete. If any sign of arcing,
severe connector corrosion, burns, cracks or
other damage is noticed, obtain new spark
plug (HT) leads, renewing them as a set.
5Spring back the retaining clips or undo the
two screws and remove the distributor cap.
Thoroughly clean it inside and out with a dry
lint-free rag.
6Examine the HT lead segments inside the
cap. If they appear badly burned or pitted
renew the cap. Also check the carbon brush
in the centre of the cap, ensuring that it is free
to move and stands proud of its holder. Make
sure that there are no signs of cracks or black
“tracking” lines running down the inside of the
cap, which will also mean renewal if evident.
7Inspect the rotor arm checking it for
security and also for signs of deterioration as
described above.
8Refit the distributor cap on completion.
33 Spark plug renewal
1
1It is vital for the correct running, full
performance and proper economy of the
engine that the spark plugs perform with
maximum efficiency. The most important
factor in ensuring this, is that the plugs fitted
are appropriate for the engine (a suitable type
is specified at the end of this Chapter). If this
type is used and the engine is in good
condition, the spark plugs should not need
attention between scheduled renewal
intervals. Spark plug cleaning is rarely
necessary, and should not be attempted
unless specialised equipment is available, as
damage can easily be caused to the firing
ends.
2Spark plug removal and refitting requires a
spark plug socket, with an extension which
can be turned by a ratchet handle or similar.
This socket is lined with a rubber sleeve, to
protect the porcelain insulator of the spark
plug, and to hold the plug while you insert it
into the spark plug hole. You will also need a
wire-type feeler gauge, to check and adjust
the spark plug electrode gap, and a torque
wrench to tighten the new plugs to the
specified torque.
3To remove the spark plugs, open the
bonnet, where fitted, release the three plastic
retaining lugs and lift the ignition shield off the
front of the engine
4If the marks on the original-equipment HT
leads cannot be seen, mark the leads 1 to 4,
to correspond to the cylinder the lead serves.
5Pull the leads from the plugs by gripping
the rubber boot, not the lead, otherwise the
lead connection may be fractured (see
illustration).
6Unscrew the spark plugs, ensuring that the
socket is kept in alignment with each plug - if
the socket is forcibly moved to either side, the
porcelain top of the plug may be broken off. If
any undue difficulty is encountered when
unscrewing any of the spark plugs, carefully
check the cylinder head threads and sealing
surfaces for signs of wear, excessive
corrosion or damage; if any of these
conditions is found, seek the advice of a
dealer as to the best method of repair.
7As each plug is removed, examine it as
follows - this will give a good indication of the
condition of the engine. If the insulator nose of
the spark plug is clean and white, with no
deposits, this is indicative of a weak mixture.
8If the tip and insulator nose are covered
with hard black-looking deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
9If the insulator nose is covered with light tan
to greyish-brown deposits, then the mixture is
correct, and it is likely that the engine is in
good condition.
10 The spark plug electrode gap is of
considerable importance as, if it is too large or
too small, the size of the spark and its
efficiency will be seriously impaired. The gap
should be set to the value given in the
Specifications.
11 To set the electrode gap, measure the
gap with a feeler blade or adjusting tool, and
then bend open, or closed, the outer plug
electrode until the correct gap is achieved
(see illustration). The centre electrode should
never be bent, as this may crack the insulation
and cause plug failure, if nothing worse. If the
outer electrode is not exactly over the centre
electrode, bend it gently to align them.
12 Before fitting the spark plugs, check that
the threaded connector sleeves at the top of
the plugs are tight, and that the plug exterior
surfaces and threads are clean (see Haynes
Hint).
13 On installing the spark plugs, first check
that the cylinder head thread and sealing
surface are as clean as possible; use a clean
rag wrapped around a paintbrush to wipe
clean the sealing surface. Ensure that the
spark plug threads are clean and dry then
screw them in by hand where possible. Take
extra care to enter the plug threads correctly.
14 When each spark plug is started correctly
on its threads, screw it down until it just seats
lightly, then tighten it to the specified torque
wrench setting.
15 Reconnect the HT leads in their correct
order, using a twisting motion on the boot
until it is firmly seated. Finally, refit the ignition
shield.
Every 12 000 miles or 12 months 1•19
1
33.5 Pull the leads off the spark plugs by
gripping the rubber boot 33.11 Adjusting a spark plug electrode
gap
It is very often difficult to insert spark
plugs into their holes without cross-
threading them. To avoid this
possibility, fit a short length of 5/16 inch
internal diameter rubber hose over the
end of the spark plug. The flexible hose
acts as a universal joint to help align
the plug with the plug hole. Should the
plug begin to cross-thread, the hose
will slip on the spark plug, preventing
thread damage to the aluminium
cylinder head
If new spark plug leads are
to be fitted, remove the
leads one at a time and fit
each new lead in exactly the
same position as the old one.
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Mini COOPER S Workshop Manual

Category
Cars
Type
Workshop Manual

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